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Case Studies : Project SRT-4 gets a heart transplant!

When we last left our Project SRT-4, it had an unfortunate head gasket tear and consequently had overheated. While the stock turbo had done it’s part putting down 355 @ 25 psi, it was definitely not happy at that level of boost.

While tearing the head off for service, we’ve decided to upgrade the turbo and exhaust manifold at the same time.

Helloooooooo...... Nurse!

We are installing a DNP Performance Tubular Manifold with External wastegate option, a Pro Street Stage V turbo with a 62-1 wheel and .70 cold side, and stage V hotside with .84 A/R.

Controlling the level of boost is a 44 mm Tial wastegate, and a BLOX manual boost controller, and of course a piggybacked SAFC on top of the Toys Stage II ecu upgrade with timing controls.

The only problem now is of course, fabricating a downpipe and 02 housing for the turbo so that it mates up to the full 3 inch catback exhaust on our SRT-4.

While the motor was out of the car, we fabbed up a test 02 housing and downpipe for this vehicle due to the exhaust facing towards the rear. Unfortunately, this test downpipe was misaligned, and upon bolting it all up we found it was exiting right onto the steering rack. Bad jujus.

Ouch....

Because of the engine layout and the choice in manifolds, the space to make this 3 inch downpipe clear is quite the challenge.

A look at the hotside and manifold setup in relation to the firewall.

A look at the clearance ( what little we have ) between the steering rack and the subframe in relation to the turbo and manifold.

A shot of the front side of the downpipe, and how close it is to the steering rack and the lines going into it.

Taking the downpipe off, we elect to gap out the top turn to push the flex section and flange away from the rack and towards the passenger side fender well.

After an hour of welding and cutting, we have successfully relocated the downpipe outlet to a more desirable location.

Next up, finishing up the job and welding the external dumptube to a tried and true location.

3 thoughts on “Case Studies : Project SRT-4 gets a heart transplant!”

How much clearance did you have between the firewall and the 70 a/r cold side? Did you have to modify the firewall at all? Or did the manifold you choose have enough of a drop to give you enough room? I’m currently working on a project with a 70 a/r cold side and it appears to need quite a bit of adjustment to the area above where the turbo is to give enough clearance..

It wasn’t much but our 02 housing is rather large and we wanted maximum clearance between the subframe and power steering lines, as I’m sure you are aware so yes we did have to slightly bang on the firewall just a tad to clear the downpipe and 02 housing from rubbing.